JP5798922B2 - Insert molded product - Google Patents

Description

  The present invention relates to an insert molded article made of a specific polycarbonate resin. More specifically, the present invention relates to an insert-molded article made of a carbonate polymer having good mechanical strength, high fluidity, high surface hardness, and containing isosorbide which is a biomass resource.

In recent years, due to concerns about the depletion of petroleum resources and the problem of increased carbon dioxide in the air that causes global warming, biomass resources that do not depend on petroleum as a raw material and that do not increase carbon dioxide even when burned are formed. In the polymer field, biomass plastics produced from biomass resources are actively developed.
A representative example of biomass plastic is polylactic acid, which has relatively high heat resistance and mechanical properties among biomass plastics, so its application is expanding to tableware, packaging materials, general merchandise, etc. Sexuality has also been considered.

However, polylactic acid is insufficient in heat resistance when used as an industrial material, and when a molded product is obtained by injection molding with high productivity, the crystalline polymer has low crystallinity. There is a problem that moldability is inferior.
As an amorphous polycarbonate resin that uses biomass resources as a raw material and has high heat resistance, a polycarbonate resin using a raw material obtained from an ether diol residue that can be produced from a saccharide has been studied.
For example, the following formula (a)

The ether diol shown in Fig. 2 is easily made from, for example, sugars and starch, and three stereoisomers are known. Specifically, the following formula (b)

1,4: 3,6-dianhydro-D-sorbitol (hereinafter referred to as “isosorbide”), represented by the following formula (c)

1,4: 3,6-dianhydro-D-mannitol (hereinafter referred to as “isomannide”), represented by the following formula (d):

1,4: 3,6-dianhydro-L-iditol (hereinafter referred to as “isoidid”).
Isosorbide, isomannide, and isoidide are obtained from D-glucose, D-mannose, and L-idose, respectively. For example, isosorbide can be obtained by hydrogenating D-glucose and then dehydrating it using an acid catalyst.

  So far, among the above-mentioned ether diols, in particular, incorporation into polycarbonate using isosorbide as a monomer has been studied. In particular, isosorbide homopolycarbonates are described in Patent Documents 1 and 2 and Non-Patent Documents 1 and 2. Among these, Patent Document 1 reports a homopolycarbonate having a melting point of 203 ° C. using a melt transesterification method. In Non-Patent Document 1, a homopolycarbonate having a glass transition temperature of 166 ° C. is obtained in the melt transesterification method using zinc acetate as a catalyst, but the thermal decomposition temperature (5% weight loss temperature) is 283 ° C. Stability is not enough. In Non-Patent Document 2, homopolycarbonate is obtained by interfacial polymerization using bischloroformate of isosorbide, but the glass transition temperature is 144 ° C. and heat resistance (particularly heat resistance due to moisture absorption) is not sufficient. On the other hand, as an example of high heat resistance, Patent Document 2 reports a polycarbonate having a glass transition temperature of 170 ° C. or higher by differential calorimetry at a heating rate of 10 ° C./min. In this case, in order to obtain a molded product by injection molding or the like, there is a problem that since the glass transition temperature is high, the molding processing temperature becomes high and the decomposition of the polymer is promoted.

In other words, it is a polycarbonate resin using isosorbide as a monomer, and can provide insert molded products that have melt flow characteristics and heat stability suitable for injection molding, and that exhibit excellent heat resistance, mechanical characteristics, and environmental resistance characteristics. Was not yet obtained.
Conventionally, decorative molded products in which the surface of an adherend of a resin molded product is decorated have been used for various purposes. For example, in the injection molding simultaneous decorating method disclosed in Patent Document 3 and the like, a decorative molded product whose surface is decorated by laminating and integrating a molding decorative sheet on the surface simultaneously with molding of a resin molded product Is obtained. For example, Patent Document 3 discloses a method of manufacturing a molded article whose surface is covered with a sheet by injection molding a molding resin after forming a decorative sheet laminated with a backer layer on a mold inner wall surface, A method of manufacturing a molded product by insert molding has been proposed.

However, in insert molding, since vacuum molding is performed after injection molding, the decorative sheet surface is likely to be damaged, deformed or soiled during transfer between the vacuum molding process and the injection molding process. There's a problem. In order to solve this problem, it is proposed to laminate a protective film on the surface of the decorative sheet (Patent Documents 4 to 8).
One of the reasons why a support such as a backer layer or a protective film is necessary is the lack of fluidity of the molding resin. Polycarbonate is generally used for these molded articles, but there is a limit to further increasing fluidity while maintaining mechanical properties.
Patent Document 9 and the like describe a method of hard-coating an insert-molded product. Generally, surface hardness is also required for molding materials for electric and electronic parts such as mobile phones and PDAs (Personal Digital Assistants). The That is, it was a potential demand to further improve the surface hardness of polycarbonate mainly used as a molding resin.

British Patent Application No. 1079686 International Publication No. 2007/013463 Pamphlet Japanese Patent Publication No. 8-2550 JP-A-10-329169 JP-A-10-329170 JP 2001-145981 A JP 2002-240202 A JP 2002-360809 A JP 2008-32928 A

“Journal of Applied Polymer Science”, 2002, Vol. 86, pp. 872-880. “Macromolecules”, 1996, Vol. 29, p. 8077-8082

An object of the present invention is to provide an insert molded article made of a polycarbonate resin having a good mechanical strength, a high surface hardness, and a biomass resource.
As a result of diligent research to achieve such an object, the present inventors have used a polycarbonate resin having a specific structure and melt flow characteristics, thereby providing an insert having excellent mechanical characteristics, high surface hardness, and excellent environmental resistance characteristics. The inventors found that a molded product can be obtained and completed the present invention.

That is, according to the present invention, the following inventions are provided.
1. A molded article formed of a polycarbonate resin including a film and a substrate formed of an acrylic resin , the substrate including a structural unit derived from a dihydroxy compound represented by the following formula (a).

2. The polycarbonate resin has a melt viscosity measured by a capillary rheometer at 240 ° C. in the range of 0.01 × 10 ^{3 to} 0.30 × 10 ³ Pa · s under the condition of a shear rate of 6080 sec ^−1. Goods.
3. 2. The molded article according to item 1, wherein the content of the structural unit derived from the dihydroxy compound represented by formula (a) in the polycarbonate resin is 100 to 30 mol% with respect to the total carbonate bond units .

4 . (I) Insert a film formed of acrylic resin into the mold,
(Ii) The following formula (a)

A polycarbonate resin containing a structural unit derived from a dihydroxy compound represented by is injected into a mold and molded.
A method for manufacturing an insert-molded product including each step.
5 . Polycarbonate resin, the melt viscosity measured at a capillary rheometer at 240 ° C., prepared in the preceding paragraph 4, wherein the range of ^{0.01 × 10 3 ~0.30 × 10 3} Pa · s under the conditions of a shear rate 6080Sec ^-1 Method.
6 . Content of units derived from a dihydroxy compound represented by the formula in the polycarbonate resin (a) prepared how the preceding paragraph 4, wherein the 100 to 30 mol% based on the total carbonate bond units.

  The molded article of the present invention is obtained from a polycarbonate resin made from biomass resources, and has high mechanical strength and surface hardness. According to the production method of the present invention, since the polycarbonate resin excellent in melt flow characteristics is used, the obtained insert molded product defect rate is low.

  Hereinafter, the molded article of the present invention will be described.

<Molded product>
(Off Irumu)
Off Irumu performs a decorative resin molded article, further abrasion resistant, hard coat properties such as high surface hardness, like those which confer solvent resistance.
Off Irumu Te present invention smell is obtained by forming a decorative layer on one surface of the film. Examples of the method for forming the decorative layer include a method of applying ink by a known printing method or coating method. Specifically, various conventionally known methods such as a gravure printing method, a flexographic printing method, a silk screen printing method, an offset printing method, a roll coating method, a gravure coating method, and a comma coating method can be used. As the ink used for forming the decorative layer, a known thermoplastic resin such as an acrylic resin, a polyvinyl resin, a polyester resin, a polyurethane resin, or a polyamide resin can be used as a binder.
In the case of a metallic decorative layer, the ink contains a high-intensity pigment as an essential component. For example, aluminum pigments such as non-leafing aluminum paste (trade name manufactured by Showa Aluminum Powder Co., Ltd.), iridium (trade name manufactured by Merck Co., Ltd.) A known high-luminance pigment such as a pearl pigment is used. As an example of the preferable commercial item of the said aluminum pigment, the pigment or dye of a suitable color can also be contained as a coloring agent.

Further, as a method other than the printing method and the coating method, the metallic decorative layer can be formed by a known method such as a vacuum deposition method, a sputtering method, an ion plating method, or a plating method. A known metal can be used as the decorative layer, but it is preferable to use aluminum, indium, or an alloy containing these with excellent malleability from the viewpoint of in-mold moldability.
As decorating method, the decorative layer on the film as a base are laminated, that have a method to paste the decorative sheet for injection molding the hard coat layer is laminated at the time of molding the resin molded product is known as the outermost layer .
Off Irumu it is formed of acrylic resin.
The total thickness of the full Irumu is preferably in the range of 20 to 200 [mu] m, more preferably 50 to 150 [mu] m, more preferably from 60～140Myuemu.

(Base material)
In the present invention, the polycarbonate resin (component A) forming the substrate has a melt viscosity measured by a capillary rheometer at 240 ° C. of 0.01 × 10 ^{3 to} 0.3 × 10 ³ under the condition of a shear rate of 6080 sec ^−1. Those within the range of Pa · s are preferred, more preferably within the range of 0.01 × 10 ^{3 to} 0.25 × 10 ³ Pa · s, and more preferably 0.01 × 10 ^{3 to} 0.24 × 10 ³ Pa. -More preferably in the range of s. When the melt viscosity is within this range, it is effective for suppressing resin stay traces (flow marks) generated in the mold during injection molding, and especially during insert molding, the effect on the insert material is reduced. It is effective in reducing the defective rate.
The content of the unit derived from the dihydroxy compound represented by the formula (a) in the polycarbonate resin is preferably 100 to 30 mol%, more preferably 100 to 40 mol%, still more preferably based on the total carbonate bond units. 100 to 50 mol%. As another component, the aliphatic diol residue derived from an aliphatic dihydroxy compound can further be included. The aliphatic dihydroxy compound is preferably a linear aliphatic diol or an alicyclic diol.
Furthermore, as other components, an aromatic diol residue derived from an aromatic dihydroxy compound can be included.

  The polycarbonate resin used in the present invention has the following formula (a):

It can manufacture with the melt polymerization method from the ether diol and carbonic acid diester represented by these. Specific examples of the ether diol include isosorbide, isomannide, and isoidide represented by the following formulas (b), (c), and (d).

These saccharide-derived ether diols are substances obtained from natural biomass and are one of so-called renewable resources. Isosorbide is obtained by hydrogenating D-glucose obtained from starch and then dehydrating it. Other ether diols can be obtained by the same reaction except for the starting materials.
In particular, a polycarbonate resin in which the carbonate structural unit includes a carbonate structural unit derived from isosorbide (1,4: 3,6-dianhydro-D-sorbitol) is preferable. Isosorbide is an ether diol that can be easily made from starch, and can be obtained in abundant resources, and is superior in all ease of manufacture, properties, and versatility of use compared to isomannide and isoidide. .

  On the other hand, in the present invention, examples of other diol compounds that can be used together with plant-derived ether diols include linear aliphatic diol compounds, alicyclic diol compounds, and aromatic dihydroxy compounds. These can be used alone or in combination.

  Examples of linear aliphatic diol compounds include ethylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, neopentyl glycol, 1,6-hexanediol, and 1,7-heptanediol. 1,8-octanediol, 2-ethyl-1,6-hexanediol, 2,2,4-trimethyl-1,6-hexanediol, 1,10-decanediol, hydrogenated dilinoleyl glycol, hydrogenated And dioleyl glycol. Of these, 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, and 1,10-decanediol are preferable. These linear aliphatic diols may be used alone or in combination of two or more.

  Examples of the alicyclic diol include 1,2-cyclohexanediol, 1,3-cyclohexanediol, 1,4-cyclohexanediol, cyclohexanediol such as 2-methyl-1,4-cyclohexanediol, and 1,2- Cyclohexanedimethanol, 1,3-cyclohexanedimethanol, cyclohexanedimethanol such as 1,4-cyclohexanedimethanol, 2,3-norbornanedimethanol, norbornanedimethanol such as 2,5-norbornanedimethanol, tricyclodecanedi Methanol, pentacyclopentadecane dimethanol, 1,3-adamantanediol, 2,2-adamantanediol, decalin dimethanol and 3,9-bis (2-hydroxy-1,1-dimethylethyl) -2,4,8, 10- Tiger-oxa-spiro [5.5] undecane. Among these, 1,4-cyclohexanedimethanol, tricyclodecane dimethanol, 3,9-bis (2-hydroxy-1,1-dimethylethyl) -2,4,8,10-tetraoxaspiro [5. 5] Undecane is preferred. These alicyclic diols may be used alone or in combination of two or more.

  Examples of the aromatic dihydroxy compound include 4′-biphenol, 3,3 ′, 5,5′-tetrafluoro-4,4′-biphenol, and α, α′-bis (4-hydroxyphenyl) -o-diisopropyl. Benzene, α, α′-bis (4-hydroxyphenyl) -m-diisopropylbenzene (usually referred to as “bisphenol M”), α, α′-bis (4-hydroxyphenyl) -p-diisopropylbenzene, α , Α′-bis (4-hydroxyphenyl) -m-bis (1,1,1,3,3,3-hexafluoroisopropyl) benzene, 9,9-bis (4-hydroxyphenyl) fluorene, 9,9 -Bis (4-hydroxy-3-methylphenyl) fluorene, 9,9-bis (3-fluoro-4-hydroxyphenyl) fluorene, 9,9-bi (4-hydroxy-3-trifluoromethylphenyl) fluorene, 1,1-bis (4-hydroxyphenyl) cyclohexane, 1,1-bis (4-hydroxyphenyl) -3,3,5-trimethylcyclohexane, , 1-bis (4-hydroxyphenyl) -4-isopropylcyclohexane, 1,1-bis (3-cyclohexyl-4-hydroxyphenyl) cyclohexane, 1,1-bis (4-hydroxyphenyl) cyclopentane, 1,1 -Bis (3-fluoro-4-hydroxyphenyl) cyclohexane, 1,1-bis (4-hydroxyphenyl) perfluorocyclohexane, 4,4'-dihydroxydiphenyl ether, 4,4'-dihydroxy-3,3 '-Dimethyldiphenyl ether, 4,4'-dihydroxydiphenyl Lufone, 4,4'-dihydroxydiphenyl sulfoxide, 4,4'-dihydroxydiphenyl sulfide, 3,3'-dimethyl-4,4'-dihydroxydiphenyl sulfide, 3,3'-dimethyl-4,4'-dihydroxydiphenyl Sulfone, 4,4′-dihydroxydiphenyl sulfone, 4,4′-dihydroxy-3,3′-diphenyl sulfide, 4,4′-dihydroxy-3,3′-diphenyl sulfoxide, 4,4′-dihydroxy-3, 3′-diphenylsulfone, 1,1-bis (4-hydroxyphenyl) methane, 1,1-bis (4-hydroxyphenyl) ethane, 2,2-bis (4-hydroxyphenyl) propane (usually “bisphenol A”) 1,1-bis (4-hydroxyphenyl) -1-pheny Ethane, 2,2-bis (4-hydroxy-3-methylphenyl) propane (usually referred to as “bisphenol C”), 2,2-bis (4-hydroxyphenyl) butane, 2,2-bis (4 -Hydroxyphenyl) pentane, 2,2-bis (4-hydroxy-3-phenylphenyl) propane, 2,2-bis (3-isopropyl-4-hydroxyphenyl) propane, 2,2-bis (3-tert-butyl) -4-hydroxyphenyl) propane, 2,2-bis (4-hydroxyphenyl) butane, 4,4-bis (4-hydroxyphenyl) heptane, 2,2-bis (4-hydroxyphenyl) octane, 1,1 -Bis (4-hydroxyphenyl) decane, 1,1-bis (3-methyl-4-hydroxyphenyl) decane, 1,1-bis (2,3- Dimethyl-4-hydroxyphenyl) decane, 2,2-bis (3-bromo-4-hydroxyphenyl) propane, bis (4-hydroxyphenyl) diphenylmethane, 1,1-bis (4-hydroxyphenyl) -4-isopropylcyclohexane 2,2-bis (4-hydroxyphenyl) -1,1,1,3,3,3-hexafluoropropane (usually referred to as “bisphenol AF”), 2,2-bis (4-hydroxy- 3-methylphenyl) -1,1,1,3,3,3-hexafluoropropane, 2,2-bis (3,5-dimethyl-4-hydroxyphenyl) -1,1,1,3,3 3-hexafluoropropane, 2,2-bis (3-fluoro-4-hydroxyphenyl) -1,1,1,3,3,3-hexafluoropropane, and 2 2-bis (3,5-difluoro-4-hydroxyphenyl) -1,1,1,3,3,3-hexafluoropropane, 2,2-bis (3,5-dibromo-4-hydroxyphenyl) propane 2,2-bis (3,5-dichloro-4-hydroxyphenyl) propane, 2,2-bis (3,5-dimethyl-4-hydroxyphenyl) propane and 2,2-bis (3-cyclohexyl-4) -Hydroxyphenyl) propane.

Among the above, bisphenol M, 9,9-bis (4-hydroxy-3-methylphenyl) fluorene, 1,1-bis (4-hydroxyphenyl) cyclohexane, 1,1-bis (4-hydroxyphenyl) -3 , 3,5-trimethylcyclohexane, 3,3′-dimethyl-4,4′-dihydroxydiphenyl sulfide, bisphenol A, bisphenol C, bisphenol AF, and 1,1-bis (4-hydroxyphenyl) decane are preferred. These aromatic diols may be used alone or in combination of two or more.
The diol residue derived from the other diol compound is preferably 0 to 70 mol%, more preferably 0 to 60 mol%, still more preferably 0 to 50 mol%, based on all diol residues. Contained in polycarbonate resin.

The reaction temperature is preferably as low as possible in order to suppress decomposition of the ether diol and obtain a highly viscous resin with little coloration, but the polymerization temperature is 180 ° C. to 280 ° C. in order to proceed the polymerization reaction appropriately. It is preferably in the range of ° C, more preferably in the range of 180 ° C to 260 ° C.
In the initial stage of the reaction, ether diol and carbonic acid diester are heated at normal pressure and pre-reacted, and then gradually reduced in pressure, and the system is changed to 1.3 × 10 ^{−3 to} 1.3 × 10 ^{− in the} late stage of the reaction. A method of facilitating the distillation of alcohol or phenol produced by reducing the pressure to about ⁵ MPa is preferred. The reaction time is usually about 0.5 to 4 hours.

Examples of the carbonic acid diester include esters such as an aryl group or aralkyl group having 6 to 12 carbon atoms, or an alkyl group having 1 to 4 carbon atoms, in which a hydrogen atom may be substituted. Specific examples include diphenyl carbonate, bis (chlorophenyl) carbonate, m-cresyl carbonate, dinaphthyl carbonate, bis (diphenyl) carbonate, dimethyl carbonate, diethyl carbonate, and dibutyl carbonate. Diphenyl carbonate is preferred.
The carbonic acid diester is preferably mixed so as to have a molar ratio of 1.02 to 0.98 with respect to the ether diol, more preferably 1.01 to 0.98, and still more preferably 1.01 to 0.8. 99. If the molar ratio of the carbonic acid diester is more than 1.02, the carbonic acid diester residue acts as a terminal block and a sufficient degree of polymerization cannot be obtained, which is not preferable. Even when the molar ratio of carbonic acid diester is less than 0.98, a sufficient degree of polymerization cannot be obtained, which is not preferable.

Examples of the polymerization catalyst include sodium hydroxide, potassium hydroxide, sodium carbonate, potassium carbonate, sodium hydrogen carbonate, alkali metal compounds such as sodium salt or potassium salt of dihydric phenol, calcium hydroxide, barium hydroxide, magnesium hydroxide, etc. And alkaline earth metal compounds, nitrogen-containing basic compounds such as tetramethylammonium hydroxide, tetraethylammonium hydroxide, tetrabutylammonium hydroxide, trimethylamine, and triethylamine. These may be used alone or in combination of two or more. Among these, it is preferable to use a nitrogen-containing basic compound and an alkali metal compound in combination. Those polymerized using these catalysts are preferred because the 5% weight loss temperature is kept sufficiently high.
The amount of these polymerization catalysts used is preferably in the range of 1 × 10 ⁻⁹ to 1 × 10 ⁻³ equivalents, more preferably 1 × 10 ^{−8 to} 5 × 10 ⁻⁴ equivalents, relative to 1 mol of the carbonic acid diester component. Chosen by The reaction system is preferably maintained in an atmosphere of a gas inert to the raw material such as nitrogen, the reaction mixture, and the reaction product. Examples of inert gases other than nitrogen include argon. Furthermore, you may add additives, such as antioxidant, as needed.

  The polycarbonate resin obtained by carrying out the reaction as described above has a hydroxyl group or a carbonic acid diester residue as the terminal structure, but the polycarbonate resin used in the present invention introduces a terminal group separately as long as the characteristics are not impaired. You may do it. Such end groups can be introduced by adding a monohydroxy compound during polymerization. As the monohydroxy compound, a hydroxy compound represented by the following formula (2) or (3) is preferably used.

In the above formulas (2) and (3), R ¹ is an alkyl group having 4 to 30 carbon atoms, an aralkyl group having 7 to 30 carbon atoms, a perfluoroalkyl group having 4 to 30 carbon atoms, or the following formula ( 4)

Preferably an alkyl group having 4 to 20 carbon atoms, a perfluoroalkyl group having 4 to 20 carbon atoms, or the above formula (4), particularly an alkyl group having 8 to 20 carbon atoms, or the above formula. (4) is preferred. X is preferably at least one bond selected from the group consisting of a single bond, ether bond, thioether bond, ester bond, amino bond and amide bond, more preferably selected from the group consisting of a single bond, ether bond and ester bond. It is at least one kind of bond, and among them, a single bond and an ester bond are preferable. a is an integer of 1 to 5, preferably an integer of 1 to 3, and 1 is particularly preferable.

In the above formula (4), R ² , R ³ , R ⁴ , R ⁵ and R ⁶ are each independently an alkyl group having 1 to 10 carbon atoms, a cycloalkyl group having 6 to 20 carbon atoms, It is at least one group selected from the group consisting of an alkenyl group having 2 to 10 carbon atoms, an aryl group having 6 to 10 carbon atoms and an aralkyl group having 7 to 20 carbon atoms, preferably each independently a carbon atom. And at least one group selected from the group consisting of an alkyl group having 1 to 10 carbon atoms and an aryl group having 6 to 10 carbon atoms, particularly at least one group selected from the group consisting of a methyl group and a phenyl group, respectively. Is preferred. b is an integer of 0 to 3, an integer of 1 to 3 is preferable, and an integer of 2 to 3 is particularly preferable. c is an integer of 4 to 100, preferably an integer of 4 to 50, and particularly preferably an integer of 8 to 50. Since the polycarbonate resin (component A) used in the present invention has a carbonate structural unit obtained from the ether diol of the renewable resource represented by the above formula (a) in the main chain structure, these monohydroxy compounds can also be planted. It is preferable that it is a raw material obtained from renewable resources, such as. Examples of monohydroxy compounds obtained from plants include long-chain alkyl alcohols having 14 or more carbon atoms (cetanol, stearyl alcohol, behenyl alcohol) obtained from vegetable oils.

By introducing these terminal groups, the effect of improving the moisture absorption resistance or surface energy property (antifouling property or abrasion resistance) of the insert molded product made of the polycarbonate resin can be obtained. These terminal groups are preferably contained in an amount of 0.3 to 9.0% by weight, more preferably 0.3 to 7.5% by weight, particularly preferably 0.3 to 9.0% by weight based on the polymer main chain structure. 5 to 6.0% by weight is contained.
You may form a base material from the resin composition which added various components to the above-mentioned polycarbonate resin. These usable components are exemplified below.

(I) Inorganic filler In the resin composition constituting the insert molded product of the present invention, when an inorganic filler is further blended, a molded product excellent in mechanical characteristics, dimensional characteristics and the like can be obtained.
As inorganic fillers, various inorganic fillers generally known such as glass fiber, carbon fiber, glass flake, wollastonite, kaolin clay, mica, talc and various whiskers (potassium titanate whisker, aluminum borate whisker, etc.) Materials can be mentioned. The shape of the inorganic filler can be freely selected from fibrous, flaky, spherical and hollow shapes, and fibrous and flaky materials are suitable for improving the strength and impact resistance of the resin composition.
Among them, the inorganic filler is preferably an inorganic filler made of a pulverized product of natural mineral, more preferably an inorganic filler made of a pulverized product of a natural mineral of silicate, and from the point of its shape. Are preferably mica, talc, and wollastonite.
On the other hand, since these inorganic fillers are non-petroleum resource materials compared to petroleum resource materials such as carbon fibers, raw materials with a lower environmental load are used, and as a result, A component with a lower environmental load is used. There is an effect that the significance of use is further enhanced. Furthermore, the above-mentioned more preferable inorganic filler has an advantageous effect that good flame retardancy is exhibited as compared with carbon fiber and the like.

The mica that can be used in the present invention is 10 to 10 expressed in terms of a number average particle diameter calculated by a total number of 1,000 particles whose average particle diameter is observed with a scanning electron microscope and extracted those having a size of 1 μm or more. 500 micrometers is preferable, More preferably, it is 30-400 micrometers, More preferably, it is 30-200 micrometers, Most preferably, it is 35-80 micrometers. When the number average particle diameter is less than 10 μm, the impact strength may be lowered. On the other hand, if it exceeds 500 μm, the impact strength is improved, but the appearance tends to deteriorate.
As the thickness of mica, one having a thickness measured by electron microscope observation of 0.01 to 10 μm can be used. Preferably 0.1-5 micrometers thing can be used. An aspect ratio of 5 to 200, preferably 10 to 100 can be used. The mica used is preferably mascobite mica, and its Mohs hardness is about 3. Muscovite mica can achieve higher rigidity and strength than other mica such as phlogopite, and a more suitable insert molded product is provided.
In addition, as a method for pulverizing mica, a dry pulverization method of pulverizing raw mica ore with a dry pulverizer, and coarsely pulverizing mica rough ore with a dry pulverizer, followed by adding a grinding aid such as water in a slurry state There is a wet pulverization method in which main pulverization is performed by a wet pulverizer, followed by dehydration and drying. The mica of the present invention can be produced by any pulverization method, but the dry pulverization method is generally lower in cost. On the other hand, the wet pulverization method is effective for pulverizing mica more thinly and finely, but is expensive. Mica may be surface-treated with various surface treatment agents such as silane coupling agents, higher fatty acid esters, and waxes, and further granulated with sizing agents such as various resins, higher fatty acid esters, and waxes to form granules. May be.

The talc that can be used in the present invention is a scaly particle having a layered structure, which is a hydrous magnesium silicate in terms of chemical composition, and is generally represented by the chemical formula 4SiO ₂ .3MgO.2H ₂ O. the SiO ₂ 56-65 wt%, the MgO 28 to 35 wt%, and a _{H 2} O about 5 wt%. As other minor components, Fe ₂ O ₃ is 0.03 to 1.2% by weight, Al ₂ O ₃ is 0.05 to 1.5% by weight, CaO is 0.05 to 1.2% by weight, K ₂ O. Is 0.2 wt% or less, Na ₂ O is 0.2 wt% or less, the specific gravity is about 2.7, and the Mohs hardness is 1.
The average particle diameter of talc that can be used in the present invention is preferably 0.5 to 30 μm. The average particle size is a particle size at a 50% stacking rate obtained from the particle size distribution measured by the Andreazen pipette method measured according to JIS M8016. The particle diameter of talc is more preferably 2 to 30 μm, further preferably 5 to 20 μm, and most preferably 10 to 20 μm. Talc in the range of 0.5 to 30 μm imparts a good surface appearance and flame retardancy to the insert molded product in addition to rigidity and low anisotropy.
In addition, there is no particular restriction on the manufacturing method when talc is crushed from raw stone, and the axial flow mill method, the annular mill method, the roll mill method, the ball mill method, the jet mill method, the container rotary compression shearing mill method, etc. are used. can do. Further, the talc after pulverization is preferably classified by various classifiers and having a uniform particle size distribution. There are no particular restrictions on the classifier, impactor type inertial force classifier (variable impactor, etc.), Coanda effect type inertial force classifier (elbow jet, etc.), centrifugal field classifier (multistage cyclone, microplex, dispersion separator) , Accucut, Turbo Classifier, Turboplex, Micron Separator, and Super Separator).

Further, talc is preferably in an agglomerated state in view of its handleability and the like, and as such a production method, there are a method by deaeration compression, a method of compression using a sizing agent, and the like. In particular, the method by deaeration and compression is preferable because it is simple and does not include unnecessary sizing agent resin components in the molded article of the present invention.
The wollastonite that can be used in the present invention is substantially represented by the chemical formula CaSiO ₃ , and usually SiO ₂ is about 50 wt% or more, CaO is about 47 wt% or more, and other Fe ₂ O ₃ and Al ₂ O _3. Etc. Wollastonite is a white acicular powder obtained by crushing and classifying raw wollastonite, and has a Mohs hardness of about 4.5. The average fiber diameter of wollastonite used is preferably 0.5 to 20 μm, more preferably 0.5 to 10 μm, and most preferably 1 to 5 μm. The average fiber diameter is observed by a scanning electron microscope, and is calculated by a total number of 1,000 fibers extracted from 0.1 μm or more.
The blending amount of these inorganic fillers is preferably 0.3 to 200 parts by weight, more preferably 1.0 to 100 parts by weight, and most preferably 3 to 50 parts by weight per 100 parts by weight of the polycarbonate resin. When the blending amount is less than 0.3 parts by weight, the reinforcing effect on the mechanical properties of the molded product of the present invention is not sufficient, and when it exceeds 200 parts by weight, the molding processability and hue deteriorate, which is not preferable. .

  In addition, in the resin composition which comprises the molded article of this invention, when using a fibrous inorganic filler and a flaky inorganic filler, the folding inhibitor for suppressing those folding can be included. The folding inhibitor inhibits adhesion between the matrix resin and the inorganic filler, reduces stress acting on the inorganic filler during melt kneading, and suppresses the folding of the inorganic filler. Examples of the effect of the folding inhibitor include (1) improvement of rigidity (increase in aspect ratio of inorganic filler), (2) improvement of toughness, and (3) improvement of conductivity (in the case of conductive inorganic filler). Can do. Specifically, the crease suppressor has (i) a compound having a low affinity with the resin, and (ii) a structure having a low affinity with the resin when the surface of the inorganic filler is directly coated with the compound. It is a compound having a functional group capable of reacting with the surface of the inorganic filler.

  Representative examples of the compound having a low affinity for the resin include various lubricants. Examples of the lubricant include mineral oil, synthetic oil, higher fatty acid ester, higher fatty acid amide, polyorganosiloxane (silicone oil, silicone rubber, etc.), olefinic wax (paraffin wax, polyolefin wax, etc.), polyalkylene glycol, fluorinated fatty acid. Fluorine oils such as esters, trifluorochloroethylene, and polyhexafluoropropylene glycol are listed.

As a method of directly coating the surface of the inorganic filler with a compound having a low affinity for the resin, (1) a method of directly immersing the compound or a solution or emulsion of the compound in the inorganic filler; A method of passing an inorganic filler in the vapor or powder of a compound, (3) a method of irradiating the inorganic filler with the powder of the compound at high speed, and (4) a mechanochemical that rubs the inorganic filler and the compound. And the like.
Examples of the compound having a structure having a low affinity with the resin and having a functional group capable of reacting with the surface of the inorganic filler include the above-described lubricants modified with various functional groups. Examples of such functional groups include a carboxyl group, a carboxylic acid anhydride group, an epoxy group, an oxazoline group, an isocyanate group, an ester group, an amino group, and an alkoxysilyl group.

One suitable folding inhibitor is an alkoxysilane compound in which an alkyl group having 5 or more carbon atoms is bonded to a silicon atom. The number of carbon atoms of the alkyl group bonded to the silicon atom is preferably 5 to 60, more preferably 5 to 20, still more preferably 6 to 18, and particularly preferably 8 to 16. The alkyl group is preferably 1 or 2, particularly preferably 1. Further, preferred examples of the alkoxy group include a methoxy group and an ethoxy group. Such alkoxysilane compounds are preferred in that they have high reactivity with the inorganic filler surface and excellent coating efficiency. Therefore, it is suitable for a finer inorganic filler.
One suitable folding inhibitor is a polyolefin wax having at least one functional group selected from a carboxyl group and a carboxylic anhydride group. The molecular weight is preferably 500 to 20,000, more preferably 1,000 to 15,000 in terms of weight average molecular weight. In such a polyolefin wax, the amount of carboxyl group and carboxylic anhydride group is in the range of 0.05 to 10 meq / g per gram of lubricant having at least one functional group selected from carboxyl group and carboxylic anhydride group. Is preferable, more preferably 0.1 to 6 meq / g, and still more preferably 0.5 to 4 meq / g. It is preferable that the ratio of the functional group in the folding inhibitor is the same as the ratio of the carboxyl group and the carboxylic anhydride group in the functional group other than the carboxyl group.

A particularly preferred example of the folding inhibitor is a copolymer of an α-olefin and maleic anhydride. Such a copolymer can be produced by melt polymerization or bulk polymerization in the presence of a radical catalyst according to a conventional method. Here, as the α-olefin, those having 10 to 60 carbon atoms as an average value can be preferably exemplified. More preferable examples of the α-olefin include those having an average carbon number of 16 to 60, and more preferably 25 to 55.
The folding inhibitor is preferably 0.01 to 2 parts by weight, more preferably 0.05 to 1.5 parts by weight, more preferably 0.1 to 0.8 parts by weight per 100 parts by weight of the polycarbonate resin (component A) used in the present invention. Part by weight is more preferred.

(Ii) Organic filler In the present invention, the resin composition constituting the base material can be blended with an organic filler. Examples of the organic filler include synthetic fibers such as aramid fiber, polyester fiber, and nylon fiber, and kenaf. Natural fibers such as hemp and bamboo are exemplified. As for the organic filler, it is preferable to use natural fibers from the viewpoint of environmental load. A preferable blending amount of the organic filler is the same as that of the inorganic filler.

(Iii) Flame retardant In the present invention, a flame retardant can be blended with the resin composition constituting the substrate. Flame retardants include brominated epoxy resins, brominated polystyrenes, brominated polycarbonates, brominated polyacrylates, halogenated flame retardants such as chlorinated polyethylene, phosphate ester flame retardants such as monophosphate compounds and phosphate oligomer compounds, Organic phosphorus flame retardants other than phosphate ester flame retardants such as phosphinate compounds, phosphonate oligomer compounds, phosphonitrile oligomer compounds, phosphonic acid amide compounds, organic sulfonate alkali (earth) metal salts, borate metal salt flame retardants And organic metal salt flame retardants such as metal stannate flame retardants, silicone flame retardants, ammonium polyphosphate flame retardants, and triazine flame retardants. Separately, a flame retardant aid (for example, sodium antimonate, antimony trioxide, etc.), an anti-drip agent (polytetrafluoroethylene having fibril-forming ability, etc.), etc. may be blended and used together with the flame retardant.
Among the above-mentioned flame retardants, compounds that do not contain chlorine and bromine atoms have reduced features that are undesirable when performing incineration and thermal recycling. It is more suitable as a flame retardant in the molded article of the present invention.
The flame retardant content is preferably in the range of 0.05 to 50 parts by weight per 100 parts by weight of the polycarbonate resin (component A). If it is less than 0.05 part by weight, sufficient flame retardancy will not be exhibited, and if it exceeds 50 parts by weight, the strength and heat resistance of the molded product will be impaired.

(Iv) Thermal Stabilizer In the present invention, the resin composition constituting the base material preferably contains a phosphorus stabilizer in order to obtain a better hue and stable fluidity. In particular, a pentaerythritol-type phosphite compound represented by the following general formula (5) is preferably blended as a phosphorus stabilizer.

(Wherein R ²¹ and R ²² are each a hydrogen atom, an alkyl group having 1 to 20 carbon atoms, an aryl group having 6 to 20 carbon atoms or an alkylaryl group, an aralkyl group having 7 to 30 carbon atoms, and an alkyl group having 4 to 20 carbon atoms. A cycloalkyl group, or a 2- (4-oxyphenyl) propyl-substituted aryl group having 15 to 25 carbon atoms, wherein the cycloalkyl group and the aryl group may be substituted with an alkyl group.

More specifically, examples of the pentaerythritol type phosphite compound include distearyl pentaerythritol diphosphite, bis (2,4-di-tert-butylphenyl) pentaerythritol diphosphite, and bis (2,6 -Di-tert-butyl-4-methylphenyl) pentaerythritol diphosphite, bis (2,6-di-tert-butyl-4-ethylphenyl) pentaerythritol diphosphite, phenylbisphenol A pentaerythritol diphosphite, Examples thereof include bis (nonylphenyl) pentaerythritol diphosphite, dicyclohexylpentaerythritol diphosphite, etc. Among them, distearyl pentaerythritol diphosphite, bis (2,4-di-tert- Butylphenyl) pentaerythritol diphosphite and bis (2,6-di -tert- butyl-4-methylphenyl) pentaerythritol diphosphite.
Examples of other phosphorus stabilizers include various other phosphite compounds, phosphonite compounds, and phosphate compounds.

  Examples of the phosphite compound include triphenyl phosphite, tris (nonylphenyl) phosphite, tridecyl phosphite, trioctyl phosphite, trioctadecyl phosphite, didecyl monophenyl phosphite, dioctyl monophenyl phosphite, diisopropyl Monophenyl phosphite, monobutyl diphenyl phosphite, monodecyl diphenyl phosphite, monooctyl diphenyl phosphite, 2,2-methylenebis (4,6-di-tert-butylphenyl) octyl phosphite, tris (diethylphenyl) phos Phyto, tris (di-iso-propylphenyl) phosphite, tris (di-n-butylphenyl) phosphite, tris (2,4-di-tert-butylphenyl) phosphite Ito, and tris (2,6-di -tert- butylphenyl) phosphite and the like.

Still other phosphite compounds that react with dihydric phenols and have a cyclic structure can be used. For example, 2,2′-methylenebis (4,6-di-tert-butylphenyl) (2,4-di-tert-butylphenyl) phosphite, 2,2′-methylenebis (4,6-di-tert- Butylphenyl) (2-tert-butyl-4-methylphenyl) phosphite, 2,2′-methylenebis (4-methyl-6-tert-butylphenyl) (2-tert-butyl-4-methylphenyl) phosphite 2,2′-ethylidenebis (4-methyl-6-tert-butylphenyl) (2-tert-butyl-4-methylphenyl) phosphite.
Examples of the phosphate compound include tributyl phosphate, trimethyl phosphate, tricresyl phosphate, triphenyl phosphate, trichlorophenyl phosphate, triethyl phosphate, diphenyl cresyl phosphate, diphenyl monoorthoxenyl phosphate, tributoxyethyl phosphate, dibutyl phosphate, dioctyl phosphate, Examples thereof include diisopropyl phosphate, and triphenyl phosphate and trimethyl phosphate are preferable.

  Examples of the phosphonite compound include tetrakis (2,4-di-tert-butylphenyl) -4,4′-biphenylenediphosphonite, tetrakis (2,4-di-tert-butylphenyl) -4,3′-biphenylenedi. Phosphonite, tetrakis (2,4-di-tert-butylphenyl) -3,3′-biphenylenediphosphonite, tetrakis (2,6-di-tert-butylphenyl) -4,4′-biphenylenediphosphonite Tetrakis (2,6-di-tert-butylphenyl) -4,3′-biphenylene diphosphonite, tetrakis (2,6-di-tert-butylphenyl) -3,3′-biphenylene diphosphonite, bis (2,4-di-tert-butylphenyl) -4-phenyl-phenylphosphonite, bis (2,4-di tert-butylphenyl) -3-phenyl-phenylphosphonite, bis (2,6-di-n-butylphenyl) -3-phenyl-phenylphosphonite, bis (2,6-di-tert-butylphenyl)- 4-phenyl-phenylphosphonite, bis (2,6-di-tert-butylphenyl) -3-phenyl-phenylphosphonite, and the like, and tetrakis (di-tert-butylphenyl) -biphenylenediphosphonite, bis (Di-tert-butylphenyl) -phenyl-phenylphosphonite is preferred, tetrakis (2,4-di-tert-butylphenyl) -biphenylenediphosphonite, bis (2,4-di-tert-butylphenyl)- More preferred is phenyl-phenylphosphonite. Such a phosphonite compound is preferable because it can be used in combination with a phosphite compound having an aryl group in which two or more alkyl groups are substituted.

Examples of the phosphonate compound include dimethyl benzenephosphonate, diethyl benzenephosphonate, and dipropyl benzenephosphonate.
Said phosphorus stabilizer can be used individually or in combination of 2 or more types, It is preferable to mix | blend an effective amount of a pentaerythritol type | mold phosphite compound at least. The phosphorus stabilizer is preferably 0.001 to 1 part by weight, more preferably 0.01 to 0.5 part by weight, still more preferably 0.01 to 0.3 part by weight per 100 parts by weight of the polycarbonate resin (component A). Partly formulated.

(V) Elastic polymer In the resin composition constituting the substrate in the present invention, an elastic polymer can be used as an impact modifier. Examples of the elastic polymer include natural rubber or glass transition temperature. One or more monomers selected from aromatic vinyl, vinyl cyanide, acrylic acid ester, methacrylic acid ester, and vinyl compounds copolymerizable therewith were copolymerized with the rubber component at 10 ° C. or lower. Mention may be made of graft copolymers. A more preferable elastic polymer is a core-shell type graft copolymer in which one or more shells of the above-mentioned monomer are graft-copolymerized on the core of the rubber component.

Moreover, the rubber component and the block copolymer of the said monomer are also mentioned. Specific examples of such block copolymers include thermoplastic elastomers such as styrene / ethylenepropylene / styrene elastomers (hydrogenated styrene / isoprene / styrene elastomers) and hydrogenated styrene / butadiene / styrene elastomers. Furthermore, various elastic polymers known as other thermoplastic elastomers such as polyurethane elastomers, polyester elastomers, polyether amide elastomers and the like can also be used.
A core-shell type graft copolymer is more suitable as an impact modifier. In the core-shell type graft copolymer, the core particle size is preferably 0.05 to 0.8 μm, more preferably 0.1 to 0.6 μm, and more preferably 0.1 to 0.5 μm in weight average particle size. Is more preferable. If it is in the range of 0.05 to 0.8 μm, better impact resistance is achieved. The elastic polymer preferably contains 40% or more of a rubber component, and more preferably contains 60% or more.

Rubber components include butadiene rubber, butadiene-acrylic composite rubber, acrylic rubber, acrylic-silicone composite rubber, isobutylene-silicone composite rubber, isoprene rubber, styrene-butadiene rubber, chloroprene rubber, ethylene-propylene rubber, nitrile rubber, ethylene- Acrylic rubber, silicone rubber, epichlorohydrin rubber, fluororubber, and those in which hydrogen is added to these unsaturated bonds may include halogen atoms because of concerns about the generation of harmful substances during combustion. No rubber component is preferable in terms of environmental load.
The glass transition temperature of the rubber component is preferably −10 ° C. or lower, more preferably −30 ° C. or lower. As the rubber component, butadiene rubber, butadiene-acrylic composite rubber, acrylic rubber, and acrylic-silicone composite rubber are particularly preferable. The composite rubber is a rubber obtained by copolymerizing two kinds of rubber components or a rubber polymerized so as to have an IPN structure entangled with each other so as not to be separated.

  Examples of the aromatic vinyl in the vinyl compound copolymerized with the rubber component include styrene, α-methylstyrene, p-methylstyrene, alkoxystyrene, halogenated styrene and the like, and styrene is particularly preferable. Examples of acrylic esters include methyl acrylate, ethyl acrylate, butyl acrylate, cyclohexyl acrylate, octyl acrylate, etc., and examples of methacrylic esters include methyl methacrylate, ethyl methacrylate, methacrylic acid. Examples thereof include butyl, cyclohexyl methacrylate, octyl methacrylate and the like, and methyl methacrylate is particularly preferable. Among these, it is particularly preferable to contain a methacrylic acid ester such as methyl methacrylate as an essential component. More specifically, the methacrylic acid ester is contained in 100% by weight of the graft component (in the case of 100% by weight of the shell in the case of the core-shell type polymer), preferably 10% by weight or more, more preferably 15% by weight or more. Is done.

  The elastic polymer containing a rubber component having a glass transition temperature of 10 ° C. or less may be produced by any polymerization method including bulk polymerization, solution polymerization, suspension polymerization, and emulsion polymerization. It can be a single-stage graft or a multi-stage graft. Moreover, the mixture with the copolymer of only the graft component byproduced in the case of manufacture may be sufficient. Furthermore, examples of the polymerization method include a general emulsion polymerization method, a soap-free polymerization method using an initiator such as potassium persulfate, a seed polymerization method, and a two-stage swelling polymerization method. In the suspension polymerization method, the aqueous phase and the monomer phase are individually maintained, both are accurately supplied to the continuous disperser, and the particle diameter is controlled by the rotation speed of the disperser, and the continuous production is performed. In the method, a method may be used in which the monomer phase is supplied by passing it through a fine orifice having a diameter of several to several tens of μm or a porous filter in an aqueous liquid having dispersibility to control the particle size. In the case of a core-shell type graft polymer, the reaction may be one stage or multistage for both the core and the shell.

Such elastic polymers are commercially available and can be easily obtained. For example, as rubber components mainly composed of butadiene rubber, acrylic rubber or butadiene-acrylic composite rubber, Kane Ace B series (for example, B-56) manufactured by Kaneka Chemical Industry Co., Ltd., manufactured by Mitsubishi Rayon Co., Ltd. Metabrene C series (for example, C-223A), W series (for example, W-450A), Paraloid EXL series (for example, EXL-2602) manufactured by Kureha Chemical Co., Ltd., HIA series (for example, HIA-15) , BTA series (eg BTA-III), KCA series, Rohm and Haas Paraloid EXL series, KM series (eg KM-336P, KM-357P etc.) and UCL modifier manufactured by Ube Saikon Resin series (UMG AB UMG AXS resin series) manufactured by Mitsubishi Rayon Co., Ltd. are commercially available under the trade name of Metabrene S-2001 or SRK-200. Are listed.
The composition ratio of the impact modifier is preferably 0.2 to 50 parts by weight per 100 parts by weight of the polycarbonate resin (component A), preferably 1 to 30 parts by weight, and more preferably 1.5 to 20 parts by weight. Such a composition range can give good impact resistance to the composition while suppressing a decrease in rigidity.

(Vi) Other additives In the resin composition constituting the substrate in the present invention, other thermoplastic resins (for example, other polycarbonate resins, aromatic polyester resins, Group polyester resin, polyarylate resin, liquid crystalline polyester resin, polyamide resin, polyimide resin, polyetherimide resin, polyurethane resin, silicone resin, polyphenylene ether resin, polyphenylene sulfide resin, polysulfone resin, polyolefin resin such as polyethylene and polypropylene, polystyrene Resin, acrylonitrile / styrene copolymer (AS resin), acrylonitrile / butadiene / styrene copolymer (ABS resin), polystyrene resin, high impact polystyrene resin, syndiotactic polystyrene tree Fats, polymethacrylate resins, phenoxy or epoxy resins, etc.), antioxidants (eg, hindered phenol compounds, sulfur antioxidants, etc.), UV absorbers (benzotriazoles, triazines, benzophenones, etc.), Light stabilizer (such as HALS), mold release agent (saturated fatty acid ester, unsaturated fatty acid ester, polyolefin wax, fluorine compound, paraffin wax, beeswax, etc.), flow modifier (such as polycaprolactone), colorant (carbon black) , Titanium dioxide, various organic dyes, metallic pigments, etc.), light diffusing agents (acrylic crosslinked particles, silicone crosslinked particles, etc.), fluorescent brighteners, phosphorescent pigments, fluorescent dyes, antistatic agents, inorganic and organic antibacterial agents, Photocatalytic antifouling agent (particulate titanium oxide, particulate zinc oxide, etc.), infrared Adsorbents, and it may be blended with such photochromic agent ultraviolet absorber. These various additives can be used in known blending amounts when blended with a thermoplastic resin such as bisphenol A polycarbonate.

(Production method of resin composition)
In the present invention, an arbitrary method is adopted for producing the resin composition constituting the substrate. For example, each component and optionally other components can be premixed and then melt-kneaded and pelletized. Examples of the premixing means include a Nauter mixer, a V-type blender, a Henschel mixer, a mechanochemical apparatus, and an extrusion mixer. In the preliminary mixing, granulation can be performed by an extrusion granulator or a briquetting machine depending on the case. After the preliminary mixing, the mixture is melt-kneaded by a melt-kneader represented by a vent type twin-screw extruder and pelletized by a device such as a pelletizer. Other examples of the melt kneader include a Banbury mixer, a kneading roll, and a constant temperature stirring vessel, but a vent type twin screw extruder is preferred. In addition, each component and optionally other components can be independently supplied to a melt-kneader represented by a twin-screw extruder without being premixed. The cylinder temperature during melt-kneading is preferably in the range of 190 to 270 ° C, more preferably in the range of 200 to 260 ° C, and still more preferably in the range of 200 to 250 ° C. When the cylinder temperature exceeds 270 ° C., the progress of thermal decomposition of the polycarbonate used in the present invention increases.

<Method of manufacturing insert molded product>
The insert-molded article of the present invention is manufactured, for example, by the following method.

[Preformation process]
In accordance with the shape of the molded product, it is a step of carrying out a preliminary molding for processing a film formed of an acrylic resin into a desired shape prior to insert molding. It is possible to insert molding in a complex three-dimensional shape off Irumu by the preforming is preferably implemented.
Examples of the preforming method include the following methods. That is, by heating while holding the previously not a full Irumu a clamp or the like, and plastically deformable to soften the skilled 該Fu Irumu. Thereafter, the softened off Irumu vacuumed through a plurality of vacuum holes of the vacuum forming mold, it is adhered along the full Irumu the shape of the mold surface. Although the method of making it adhere | attach on the metal mold | die surface does not necessarily need to be vacuum suction, vacuum suction is common. When element off Irumu is cured by cooling, off Irumu obtain the desired molded article shape is transferred.

[Trimming process]
Excess portions other than the mold mirror surface portion of the film formed of the acrylic resin obtained in the preforming step are cut out and trimmed to a desired shape. Trimming can be performed using a laser, a die-cut die or the like. Die-cutting (punching) is more common than laser.

[Insert molding process]
A film formed of an acrylic resin processed into a desired shape by a preforming and trimming process is attached to the movable side so that the backing layer side contacts the base resin. Next, the base resin is injected from the nozzle of the injection molding machine and introduced into the cavity. At that time, full Irumu is in close contact along the receiving mold pressure from the base resin. A portion of the backing layer of the full Irumu by the heat of the base resin is in close contact with each other and melted to base resin.
The above injection molding is represented by the following formula (a)

Is a step of injecting a polycarbonate resin containing a structural unit derived from the dihydroxy compound represented by

The polycarbonate resin is injection molded at a cylinder temperature of 190 to 270 ° C. In order to suppress coloring and molecular weight reduction due to decomposition of the polycarbonate resin, the temperature range is more preferably 200 to 260 ° C, and further preferably 200 to 250 ° C. When the cylinder temperature exceeds 270 ° C., the decomposition of the polycarbonate resin is greatly promoted. The mold temperature can be preferably in the range of 40 to 140 ° C., but in order to shorten the molding cycle and shorten the melt residence time of the resin, 40 to 120 ° C. is more preferable, and more preferably 40 to 100 ° C. It is a range.
Injection molding can be performed not only by a normal cold runner molding method but also by a hot runner molding method. In such injection molding, a molded product can be obtained by using an insert molding method.

<Uses of insert molded products>
The insert-molded product of the present invention is suitable, for example, as an exterior material for office automation equipment and home appliances. For example, personal computers, notebook computers, game machines (home game machines, business game machines, pachinko machines, slot machines, etc.), displays, etc. Molding devices such as devices (CRT, liquid crystal, plasma, projector, organic EL, etc.), mice, and exterior materials such as printers, copiers, scanners and fax machines (including these multifunction devices), keyboard keys and various switches Goods are illustrated. Furthermore, the insert-molded product of the present invention is useful for a wide variety of other applications, such as various lenses and recording media (CD, MD, DVD, Blu-ray (registered trademark) Disc, next-generation high-density disk, hard disk, etc.). Optical members such as substrates, portable information terminals (so-called PDAs), cellular phones, portable books (dictionaries, etc.), portable televisions, recording medium drives, recording media (IC cards, smart media, memory sticks, etc.) readers, Optical cameras, digital cameras, parabolic antennas, electric tools, VTRs, irons, hair dryers, rice cookers, microwave ovens, audio equipment, lighting equipment, refrigerators, air conditioners, air purifiers, negative ion generators, typewriters, etc. The molded product of the present invention can be applied to various parts such as exterior materials for electronic devices. . It is also suitable for electrical and electronic parts such as connectors, switches, relays and capacitors, and various miscellaneous goods such as various containers, covers, writing instrument bodies, and ornaments. Furthermore, lamp sockets, lamp reflectors, lamp housings, instrument panels, center console panels, deflector parts, car navigation parts, car audiovisual parts, harness connectors and other automotive electrical components, automotive mechanism parts, auto mobile computer parts, etc. Vehicle parts.

  Further, the insert molded product of the present invention can be further provided with other functions by surface modification. Surface modification here means a new layer on the surface of resin molded products such as vapor deposition (physical vapor deposition, chemical vapor deposition, etc.), plating (electroplating, electroless plating, hot dipping, etc.), painting, coating, printing, etc. The method used for normal resin molded products can be applied.

  Hereinafter, the present invention will be described in detail by way of examples. However, the present invention is not limited to these. A polycarbonate resin was produced by the method shown in the production examples below. Moreover, each value in an Example was calculated | required with the following method.

(1) Melt viscosity Obtained as a result of measurement using a capillary rheometer (Capillograph model 1D) manufactured by Toyo Seiki Co., Ltd. with a capillary length of 10.0 mm, a capillary diameter of 1.0 mm, and a measurement temperature of 240 ° C. The melt viscosity at 6080 sec ⁻¹ was read from the obtained Shear Rate / Viscosity curve.
(2) Glass transition temperature (glass transition point)
It was measured by DS instrument (model DSC2910) manufactured by TA Instruments.
(3) 5% weight loss temperature Measured with TGA (model TGA2950) manufactured by TA Instruments.

(4) Specific viscosity (η _sp )
The pellet was dissolved in methylene chloride, the concentration was about 0.7 g / dL, and the temperature was measured at 20 ° C. using an Ostwald viscometer (device name: RIGO AUTO VISCOSIMETER TYPE VMR-0525 · PC). In addition, specific viscosity (eta) _sp is calculated | required from a following formula.
η _sp = t / to-1
t: Flow time of sample solution to: Flow time of solvent only (5) Evaluation of scratch resistance Using the obtained insert-molded product, the resin surface and the decorative film surface were tested using a test method based on JIS K5600. Hardness was measured.

(6) Chemical resistance (solvent resistance)
The obtained insert molded product was immersed in toluene, xylene, acetone, and trichloroethane at room temperature for 24 hours, and the surface state was visually observed.
○: No effect, Δ: Partially whitened, X: Dissolved or whitened (7) Bending strength, flexural modulus Bending properties were measured according to ISO178 (test piece shape: length 80 mm × width 10 mm × thickness 4 mm) .

Example 1
As off Irumu, the following were used. “NT-HIRAMIC” (registered trademark) 701R white manufactured by Dainichi Seika Kogyo Co., Ltd. was prepared with a 2: 2: 1 mixed solution of ethyl acetate / methyl ethyl ketone / isopropyl alcohol to a printing viscosity of 15 seconds (Zahn Cup # 3). The acrylic base film was subjected to pattern printing by a gravure printing method and dried in an oven at 70 ° C. for 10 seconds to provide a 35 μm decorative layer.
A polycarbonate resin for a substrate was produced by the following method.
Isosorbide (hereinafter sometimes referred to as ISS) 1,608 parts by weight (11 moles) and diphenyl carbonate 2,356 parts by weight (11 moles) were placed in a reactor, and tetramethylammonium hydroxide as a polymerization catalyst was added in an amount of 1. 0 parts by weight (1 × 10 ⁻⁴ mol per 1 mol of diphenyl carbonate component) and 1.1 × 10 ⁻³ parts by weight of sodium hydroxide (0.25 × 10 ⁻⁶ per mol of diphenyl carbonate component) Mol) were charged and heated to 180 ° C. and melted at normal pressure in a nitrogen atmosphere.
Under stirring, the pressure in the reaction vessel was gradually reduced over 30 minutes, and the pressure was reduced to 13.3 × 10 ⁻³ MPa while the produced phenol was distilled off. After reacting in this state for 20 minutes, the temperature was raised to 200 ° C., then the pressure was gradually reduced over 20 minutes, and the reaction was carried out at 4.00 × 10 ⁻³ MPa for 20 minutes while distilling off the phenol. The mixture was heated to 250 ° C. for 30 minutes and reacted for 30 minutes.

Next, the pressure was gradually reduced, and the reaction was continued at 2.67 × 10 ⁻³ MPa for 10 minutes and 1.33 × 10 ⁻³ MPa for 10 minutes, and further reduced in pressure to reach 4.00 × 10 ⁻⁵ MPa. The temperature was gradually raised to 260 ° C., and the reaction was finally carried out at 260 ° C. and 6.66 × 10 ⁻⁵ MPa for 1 hour. The polymer after the reaction was pelletized. The specific viscosity of the obtained polymer was 0.26, the glass transition temperature was 163 ° C., and the 5% weight loss temperature was 347 ° C.
By using the resin as a molding material, to prepare an insert molded article of the full Irumu.

[Preformation process]
While holding the decorative film with a clamp, it was brought into close contact with a pre-molding mold heated to 80 ° C., and the mold was closed to process into a desired molded product shape.

[Trimming process]
Excess parts other than the mold mirror surface part of the decorative film obtained in the preforming step were cut out using scissors.

[Insert molding process]
A decorative film processed into a desired shape by a preforming and trimming process on the movable side was attached in the cavity of the mold so that the backing layer side was in contact with the base resin. The produced polycarbonate resin pellets were dried with a hot air dryer at 120 ° C. for 4 hours, and molded with a molding machine with a clamping force of 1470 kN at a cylinder temperature of 250 ° C. and a mold temperature of 80 ° C. Obtained. The insert molded product was evaluated for scratch resistance and chemical resistance test.

Example 2
Isosorbide 66.42 parts by weight (0.45 mol), 1,3-propanediol (hereinafter sometimes referred to as PD) 11.52 parts by weight (0.15 mol) and diphenyl carbonate 129.81 parts by weight (0 .61 mol) was added to the reactor, and 1.0 part by weight of tetramethylammonium hydroxide (1 × 10 ⁻⁴ mol relative to 1 mol of diphenyl carbonate component) was used as a polymerization catalyst, and 1.1% of sodium hydroxide was added. × 10 ^-3 parts by weight except for using (0.25 × 10 ^-6 mol based on diphenyl carbonate component 1 mol) and in the same manner as in example 1 were melt polymerization of polycarbonate resin. The polymer obtained had a specific viscosity of 0.25, a glass transition temperature of 116 ° C., and a 5% weight loss temperature of 338 ° C. Similarly the resin as in Example 1 by using as a molding material, to prepare an insert molded article of the full Irumu was evaluated.

Example 3
804 parts by weight (5.5 moles) of isosorbide, 1,256 parts by weight (5.5 moles) of bisphenol A (BPA) and 2,356 parts by weight (11 moles) of diphenyl carbonate were placed in a reaction vessel, and tetramethyl as a polymerization catalyst. 1.0 parts by weight of ammonium hydroxide (1 × 10 ⁻⁴ moles per mole of diphenyl carbonate component) and 1.1 × 10 ⁻³ parts by weight of sodium hydroxide (0.25 moles per mole of diphenyl carbonate component) The polycarbonate resin was subjected to melt polymerization in the same manner as in Example 1 except that × 10 ⁻⁶ mol) was used. The polymer obtained had a specific viscosity of 0.35, a glass transition temperature of 153 ° C., and a 5% weight loss temperature of 366 ° C.
Similarly the resin as in Example 1 by using as a molding material, to prepare an insert molded article of the full Irumu was evaluated.

Example 4
1,242 parts by weight (8.5 mol) of isosorbide, 490 parts by weight (1.5 mol) of 1,1-bis (4-hydroxyphenyl) decane (hereinafter sometimes abbreviated as DED), and 2, 142 parts by weight (10 moles) was put in a reaction vessel, 1.0 parts by weight of tetramethylammonium hydroxide (1 × 10 ⁻⁴ moles per mole of diphenyl carbonate component) as a polymerization catalyst, and sodium hydroxide 1.1 × 10 ^-3 parts by weight except for using (0.25 × 10 ^-6 mol based on diphenyl carbonate component 1 mol) and in the same manner as in example 1 were melt polymerization of polycarbonate resin. The polymer obtained had a specific viscosity of 0.25, a glass transition temperature of 124 ° C., and a 5% weight loss temperature of 357 ° C.
Similarly the resin as in Example 1 by using as a molding material, to prepare an insert molded article of the full Irumu was evaluated.

Example 5
1,608 parts by weight (11 moles) of isosorbide, 2,356 parts by weight (11 moles) of diphenyl carbonate and 59 parts by weight (0.22 moles) of stearyl alcohol were placed in a reactor, and tetramethylammonium hydroxide was added as a polymerization catalyst. 1.0 part by weight (1 × 10 ⁻⁴ moles per mole of diphenyl carbonate component) and 1.1 × 10 ⁻³ parts by weight of sodium hydroxide (0.25 × 10 5 parts per mole of diphenyl carbonate component) ⁻⁶ mol) was used in the same manner as in Example 1 except that melt polymerization of polycarbonate was performed. The polymer obtained had a specific viscosity of 0.28, a glass transition temperature of 150 ° C., and a 5% weight loss temperature of 362 ° C.
Similarly the resin as in Example 1 by using as a molding material, to prepare an insert molded article of the full Irumu was evaluated.

Example 6
50 parts of the polycarbonate resin pellets produced in Example 1 and 50 parts of the copolymerized polycarbonate resin pellets produced in Example 2 were mixed in a blender to obtain 87 mol% of isosorbide structural unit and 13 mol of 1,3-propanediol structural unit. % Polycarbonate resin blend was obtained. The polymer obtained had a specific viscosity of 0.26, a glass transition temperature of 140 ° C., and a 5% weight loss temperature of 348 ° C.
Similarly the resin as in Example 1 by using as a molding material, to prepare an insert molded article of the full Irumu was evaluated.

Example 7
As full Irumu, using a metallic decorative film Japan Wave Rock Co., Ltd. Super Tech mirror (trade name).
1,169 parts by weight (8 moles) of isosorbide, 2,142 parts by weight (10 moles) of diphenyl carbonate, and 236 parts by weight (2 moles) of hexanediol (hereinafter sometimes referred to as HD) are placed in a reactor and polymerized. As catalyst, 1.0 part by weight of tetramethylammonium hydroxide (1 × 10 ⁻⁴ mole relative to 1 mole of diphenyl carbonate component) and 1.1 × 10 ⁻³ part by weight of sodium hydroxide (1 mole of diphenyl carbonate component) The polymer was melt polymerized in the same manner as in Example 1 except that 0.25 × 10 ⁻⁶ mol) was used. The polymer obtained had a specific viscosity of 0.26, a glass transition temperature of 111 ° C., and a 5% weight loss temperature of 350 ° C.
By using the resin as a molding material, to prepare an insert molded article of the full Irumu.

[Preformation process]
While holding the metallic decorative film with a clamp, it was brought into close contact with a pre-molding mold heated to 80 ° C., and the mold was closed to process into a desired molded product shape.

[Trimming process]
Excess parts other than the metallic mirror surface part of the metallic decorative film obtained in the preforming step were cut out using scissors.

[Insert molding process]
A metallic decorative film processed into a desired shape by a preforming and trimming process on the movable side was mounted in the mold cavity so that the backing layer side was in contact with the base resin. The produced polycarbonate resin pellets were dried with a hot air dryer at 100 ° C. for 6 hours, and a molding machine with a clamping force of 1470 kN (manufactured by FANUC: T-150D) at a cylinder temperature of 220 ° C. and a mold temperature of 70 ° C. Molding was performed to obtain an insert molded product. The insert molded product was evaluated for scratch resistance and chemical resistance test.

Example 8
1,169 parts by weight (8 moles) of isosorbide, 2,142 parts by weight (10 moles) of diphenyl carbonate, and 236 parts by weight (2 moles) of hexanediol were placed in a reactor, and tetramethylammonium hydroxide as a polymerization catalyst was added in an amount of 1. 0 parts by weight (1 × 10 ⁻⁴ mol per 1 mol of diphenyl carbonate component) and 1.1 × 10 ⁻³ parts by weight of sodium hydroxide (0.25 × 10 ⁻⁶ per mol of diphenyl carbonate component) Mol) was used in the same manner as in Example 1 except that melt polymerization of polycarbonate was performed. The polymer obtained had a specific viscosity of 0.36, a glass transition temperature of 113 ° C., and a 5% weight loss temperature of 352 ° C.
Similarly the resin as in Example 1 by using as a molding material, to prepare an insert molded article of the full Irumu was evaluated.

Example 9
1,096 parts by weight (7.5 moles) of isosorbide, 2,142 parts by weight (10 moles) of diphenyl carbonate, and 295 parts by weight (2.5 moles) of hexanediol are placed in a reactor, and tetramethylammonium hydroxy is used as a polymerization catalyst. 1.0 parts by weight (1 × 10 ⁻⁴ moles per mole of diphenyl carbonate component) and 1.1 × 10 ⁻³ parts by weight of sodium hydroxide (0.25 moles per mole of diphenyl carbonate component) The melt polymerization of polycarbonate was carried out in the same manner as in Example 1 except that × 10 ⁻⁶ mol) was used. The polymer obtained had a specific viscosity of 0.28, a glass transition temperature of 97 ° C., and a 5% weight loss temperature of 349 ° C.
Similarly the resin as in Example 1 by using as a molding material, to prepare an insert molded article of the full Irumu was evaluated.

Example 10
1,096 parts by weight (7.5 moles) of isosorbide, 2,142 parts by weight (10 moles) of diphenyl carbonate, and 295 parts by weight (2.5 moles) of hexanediol are placed in a reactor, and tetramethylammonium hydroxy is used as a polymerization catalyst. 1.0 parts by weight (1 × 10 ⁻⁴ moles per mole of diphenyl carbonate component) and 1.1 × 10 ⁻³ parts by weight of sodium hydroxide (0.25 moles per mole of diphenyl carbonate component) The melt polymerization of polycarbonate was carried out in the same manner as in Example 1 except that × 10 ⁻⁶ mol) was used. The specific viscosity of the obtained polymer was 0.34, the glass transition temperature was 99 ° C., and the 5% weight loss temperature was 347 ° C.
Similarly the resin as in Example 8 using as a molding material, to prepare an insert molded article of the full Irumu was evaluated.

Comparative Example 1
A melt film-forming film was obtained from bisphenol A-polycarbonate resin (PC-A) in the same manner as in Example 1. Scratch resistance evaluation was performed using the obtained film. The results are shown in Table 1. Similarly the resin as in Example 1 by using as a molding material, to prepare an insert molded article of the full Irumu was evaluated.

  The insert molded product of the present invention is useful for various applications such as various optical members, electronic / electrical equipment, OA equipment, vehicle parts, machine parts, other agricultural materials, fishing materials, transport containers, packaging containers, playground equipment, and miscellaneous goods. is there.

Claims (6)

A molded article formed of a polycarbonate resin including a film and a substrate formed of an acrylic resin , the substrate including a structural unit derived from a dihydroxy compound represented by the following formula (a).

2. The polycarbonate resin has a melt viscosity measured by a capillary rheometer at 240 ° C. in a range of 0.01 × 10 ^{3 to} 0.30 × 10 ³ Pa · s under a condition of a shear rate of 6080 sec ⁻¹ . Molding.   2. The molded article according to claim 1, wherein the content of the structural unit derived from the dihydroxy compound represented by the formula (a) in the polycarbonate resin is 100 to 30 mol% with respect to the total carbonate bond units. (I) Insert a film formed of acrylic resin into the mold,
(Ii) The following formula (a)

A polycarbonate resin containing a structural unit derived from a dihydroxy compound represented by is injected into a mold and molded.
A method for manufacturing an insert-molded product including each step. Polycarbonate resin, the melt viscosity measured at a capillary rheometer at 240 ° C., according to claim 4, wherein under a condition of shear rate of 6080Sec ^-1 in the range of ^{0.01 × 10 3 ~0.30 × 10 3} Pa · s Production method. The production method according to claim 4 , wherein the content of the unit derived from the dihydroxy compound represented by the formula (a) in the polycarbonate resin is 100 to 30 mol% with respect to the total carbonate bond unit.